Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 25, Problem 51SDP
To determine
Explain the dependency of accuracy and surface finish that can be achieved in a machining center as a function of the number of inserts on a cutter.
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In an orthogonal machining with a tool of 9 degree orthogonal rake angle, the uncut chip thickness is 0.2mm.
The chip thickness fluctuates between 0.25 mm and 0.4 mm. The ratio of the maximum shear angle to the
minimum shear angle during machining is
In an orthogonal machining with a tool of 9
orthogonal rake angle, the uncut chip thickness
is 0.2 mm. The chip thickness fluctuates between
0.25 mm and 0.4 mm. The ratio of the maximum
shear angle to the minimum shear angle during
machining is
A face milling operation is used to machine 6.0 mm from the top surface of
a rectangular piece of aluminum 300 mm long by 125 mm wide in a single
pass. The cutter follows a path that is centered over the workpiece. It has
four teeth and is 150 mm in diameter. Cutting speed = 2.8 m/s, and chip load
= 0.27 mm/tooth. Determine (a) the actual machining time to make the pass
across the surface and (b) the maximum metal removal rate during cutting
Chapter 25 Solutions
Manufacturing Engineering & Technology
Ch. 25 - Describe the distinctive features of machining...Ch. 25 - Explain how the tooling system in a machining...Ch. 25 - Explain the trends in materials used for...Ch. 25 - Is there any difference between chatter and...Ch. 25 - What are the differences between forced and...Ch. 25 - Explain the importance of foundations in...Ch. 25 - Explain why automated pallet changers and...Ch. 25 - What types of materials are machine-tool bases...Ch. 25 - What is meant by the modular construction of...Ch. 25 - What is a hexapod? What are its advantages?
Ch. 25 - What factors contribute to costs in machining...Ch. 25 - List the reasons that temperature is important in...Ch. 25 - Explain the technical and economic factors that...Ch. 25 - Spindle speeds in machining centers vary over a...Ch. 25 - Explain the importance of stiffness and damping of...Ch. 25 - Are there machining operations described in...Ch. 25 - How important is the control of cutting-fluid...Ch. 25 - Review Fig. 25.10 on modular machining centers,...Ch. 25 - Prob. 19QLPCh. 25 - Describe the adverse effects of vibration and...Ch. 25 - Describe some specific situations in which thermal...Ch. 25 - Prob. 22QLPCh. 25 - Prob. 23QLPCh. 25 - Prob. 24QLPCh. 25 - List the parameters that influence the temperature...Ch. 25 - List and explain factors that contribute to poor...Ch. 25 - Prob. 27QLPCh. 25 - Prob. 28QLPCh. 25 - Describe types and sizes of workpieces that would...Ch. 25 - Prob. 30QLPCh. 25 - Explain the advantages and disadvantages of...Ch. 25 - What are the advantages and disadvantages of (a)...Ch. 25 - What would be the advantages and limitations of...Ch. 25 - Explain how you would go about reducing each of...Ch. 25 - Describe workpieces that would not be suitable for...Ch. 25 - Give examples of forced vibration or self-excited...Ch. 25 - A machining-center spindle and tool extend 10 in....Ch. 25 - Using the data given in the example, estimate the...Ch. 25 - A machining-center spindle and tool extend 12 in....Ch. 25 - In the production of a machined valve, the labor...Ch. 25 - Estimate the optimum cutting speed in Problem...Ch. 25 - Prob. 42QTPCh. 25 - If you were the chief engineer in charge of the...Ch. 25 - Prob. 45SDPCh. 25 - Make a list of components of machine tools that...Ch. 25 - The cost of machining and turning centers is...Ch. 25 - Prob. 49SDPCh. 25 - Describe your thoughts on whether or not it is...Ch. 25 - Prob. 51SDPCh. 25 - Prob. 53SDP
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- 6) It has been stated that it is generally undesirable to allow temperatures to rise excessively in machining operations. Explain why. 7) Explain the possible disadvantages of a machining operation if a discontinuous chip is produced. 8) List and explain the factors that contribute to poor surface finish in machining operations 9) Given your understanding of the basic machining process, describe the important physical and chemical properties of a cutting tool.arrow_forwardWhat is surface roughness? Surface finish is one of the most important measures for determining the quality of products in machining. Explain in some details.arrow_forwardThe following data is given for slab milling of a 300 mm long 50 mm wide mild steel block: Cutter of diameter= 60 mm; Numbers of teeth =12; Cutter speed = 120 rev/min; Depth of cut = 3.2 mm; Feed is 0.25 mm/tooth.Determine (i) Table feed in mm/min, (ii) MRR (iii) Power (iv) Torque and (v) Total machining time. Assumesuitable approach and over-run and specific energy of mild steel as 5 Ws/mm3.arrow_forward
- Calculate the machining time intervals for face milling a cutter 10 inches long, 2 inches wide, with a depth of cut of 0.1 inch for the following workpiece materials: (a) low-carbon steel ; (b) titanium alloys; (c) aluminum alloys, and (d) thermoplastics.arrow_forwardIdentify some of the reasons why machining is commercially and technologically important.arrow_forwardEstimate the machining time that will be required to finish a vertical flat surface of length 100 mm and depth 20 mm by an end mill cutter of 32 mm diameter and 60 mm length in a milling machine. Assume cutting speed of 30 m/min and feed of 0.12 mm/tooth. Let over run distance equal to approach distance.arrow_forward
- Investigate the non-traditional machining methods. Describe each in your own words and sketch out the process and appropriate scale (inches/microns etc). Then tabulate the material removal mechanism, workpiece materials, applications, costs/speed, advantages and limitations/disadvantages of each. The slides are for your starting point. List references, articles, videos, etc... Mechanical Methods 1. Water Jet Machining (WJM) 2. Abrasive Water Jet Machining (AWJM) 3. Ultrasonic Machining (USM) Non-Mechanical Methods 1. Electrochemical Machining (ECM) 2. Electro-Discharge Machining (EDM) 3. Wire EDM 4. Laser Drilling 5. Electron beam machining (EBM)arrow_forwardFor the following application, identify one or more nontraditional machining processes that might be used, and present arguments to support your selection. Assume that either the part geometry or the work material (or both) preclude the use of conventional machining. The application is a through-hole in the shape of the letter L in a 12.5 mm (0.5 in) thick plate of glass. The size of the "L" is 25 by 15 mm (1.0 by 0.6 in) and the width of the hole is 3 mm (1/8 in).arrow_forwardFollowing are the data in an orthogonal cutting operation. Rake angle = 15° Cutting speed = 20 m/min Chip thickness = 0.7 mm Width of cut = 4.5 mm Cutting ratio = 0.714 Assuming Merchant's theory, coefficient of friction at the tool-chip interface isarrow_forward
- a) It has been stated that it is generally undesirable to allow temperatures to riseexcessively in machining operations. Explain why?b) List out the cutting parameters which is influenced the rises of cuttingtemperature during turning process.c) Evaluate the relationship of these cutting parameters to the cutting temperaturewith graph.d) Propose the solution of how to reduce the temperature during the cuttingprocess.arrow_forwardDiscuss the impact of current and voltage on machining characteristics in EDM in detailarrow_forwardAssume that, in orthogonal cutting, the rake angle, oz,is 20° and the friction angle, B, is 35° at the chip-tool interface.Determine the percentage change in chip thickness when the friction angle is 50°. (Note: do not use Eq. (21.3)arrow_forward
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